Multi-ply apparel neckpiece

ABSTRACT

Multi-ply apparel neckpieces may feature sewn edges that provide increased flexibility of the apparel neckpiece in high stress areas, such as the knotting area and/or the neck area. Specifically, apparel neckpieces that feature edges sewn along a woven fabric&#39;s warp and weft are described. In at least one embodiment, an attaching thread may sew together two or more pieces of fabric, where at least one of the pieces of fabric is a woven fabric. The attaching thread may penetrate the fabric with a plurality of incision points, each pair of adjacent incision points connected by an interpoint portion of the attaching thread. The two or more pieces of fabric may be attached such that the pieces of fabric and the attaching thread are substantively at the same tension at rest.

BACKGROUND

The apparel industry has manufactured a broad range of neckwearincluding scarves and ties. For example, tie neckpieces include bowties,neckties, and other neckwear pieces. Because ties typically accompanymen's suits (i.e., casual, business, executive, tuxedo, etc.), themanufacture and/or sale of tie neckpieces generates a significant amountof revenue.

While scarves are typically loosely tied, or often not tied at all, tieneckpieces are typically knotted tightly. In the case of a necktie, thetie is drawn around the wearer's neck, knotted in front of the neck, andthe ends are displayed in the front of the wearer. In some embodiments,the ends dangle down in the front of the wearer. From some aestheticperspectives, a well formed, tight knot is considered the focal point ofa suit. Accordingly, common necktie knots may range from a simple loopto a double Windsor knot comprised of three loops. There are even moreknots that make use of loops including, but not limited to the Eldredge,Trinity, and Cape knots. Thus, a portion of the necktie comprising theknot, the knotting area, and the portion of the tie around the wearer'sneck, bears significantly more stress than the other portions of thetie.

Any fabric, including fabric used in a necktie, has limited flexibility.Specifically, a fabric's flexibility is that fabric's ability to returnsubstantially to its original shape after being stretched or otherwiseplaced under tensile stress. Neckties, and in particular the knottingarea and the portion of the tie around the wearer's neck, are stretchedand placed under uneven tensile stress. A necktie may be renderedunusable where it has been stretched to the point that it does notreturn to its original shape. In that case, the integrity of the necktiebecomes compromised when the necktie fabric has been stretched beyondits flexibility tolerance.

Neckties are typically constructed from pieces of fabric with variousflexibility tolerances. One or more additional pieces of fabric may beused as a backing and/or interlining of a necktie. The one or moreadditional pieces of fabric may also have different flexibilitytolerances. Furthermore, attaching threads, the threads used to sew theone or more pieces of fabric together, may have different flexibilitytolerances as well. Thus, if a high stress area, such as a knotting areaand/or the area around the wearer's neck, is sewn in a conventionalmanner, bunching and/or separation of individual threads may result fromcombining fabrics having different flexibility tolerances.

In one approach to avoid fabric separation, existing neckties utilizethe concept of folding, while keeping sewing to a minimum. For instance,a high end necktie may feature seven folds and have hand rolled edges,with sewing limited to a keeper loop, tag, a bar tack stitch and/or aslip stitch to prevent pieces of the necktie from separating. Due thelimited amount of sewing, fabrics with different flexibility tolerancesare rarely used for neckties, and neckties generally use a specializediron for pressing. Accordingly, folded neckties are limited in theirstructural features and the fabrics that may be used for their creation.

BRIEF DESCRIPTION OF THE DRAWINGS

The Detailed Description is set forth with reference to the accompanyingfigures. In the figures, the left-most digit(s) of a reference use ofthe same reference numbers in different figures indicates similar oridentical items.

FIG. 1 is an example illustration of a necktie and its constituentparts.

FIG. 2 is an example illustration of a multi-ply apparel neckpiece andits constituent parts.

FIG. 3 is an example illustration of a sewn edge of two or more piecesof fabric.

FIG. 4 is an example illustration of a multi-ply apparel neckpiece withundulating curves executed with articulation snips.

FIG. 5 is an example illustration of two multi-ply apparel neckpieceswith pockets for one of the ends of the apparel neckpieces.

FIG. 6 is an example flow chart of a process for manufacturing amulti-ply apparel neckpiece.

DETAILED DESCRIPTION The Context of the Apparel Neckpiece

Before discussing a shape preserving apparel neckpiece, it is useful tointroduce some terminology derived from a conventional necktie. Aconventional necktie 100 is shown with respect to FIG. 1.

A necktie 100 is generally made of at least one elongated piece offabric 102, with one end of the necktie 100 being broader than the otherend. The broader end typically has a front side 104 that is visible andmay have an aesthetic or expressive pattern. The length of the necktie100 constitutes the axis of elongation 106. When the necktie 100 isbeing worn, the axis of elongation 106 is a vertical, or anapproximately vertical, axis. The centerline (not shown) is the centerof the necktie along the axis of elongation 106 and is approximatelyparallel with respect to the axis of elongation.

Neckties 100 typically utilize folds and creases to provide structure,often with a minimum amount of sewing. In some embodiments, backliningor interfacing may be added to a necktie to provide structure. The edgesof a necktie 100 are generally not sewn, but are instead rolled.Specifically, the edge of the necktie 100 is folded over multiple times,and is then creased by a pressing process (e.g., pressing the necktiewith an iron). The pressed crease maintains the shape of the necktie's100 construction. In FIG. 1, a rolled edge 108 is shown.

Generally, a second piece of fabric is attached to a back side of thenecktie 100 to provide a backlining. In some embodiments, the attachmentmechanism used to attach the first piece of fabric to the second pieceof fabric may be an adhesive, tack stitches, or a stitch that followsthe fibers. In embodiments where the backlining shows at the tips of aback side of a necktie, that backlining is called the tip lining 110.

Sewing may be employed in a necktie 100 in several embodiments. Forexample, a brand of a necktie 100 is typically attached via a smallstrip of fabric, referred to as the tag 112, and is sewn into the backside of the necktie 100. Additionally or alternatively, the back side ofthe necktie 100 may include a small loop, usually made from a strip offabric, that is laid substantially perpendicular to the centerline ofthe necktie 100. This loop, called a keeper loop 114, may be used tohold the narrower end of a necktie 100 in a relatively fixed position.In at least one embodiment, because the keeper loop 114 may elongate anddistort at different rates, the keeper loop 114 is typically attached tothe centerline of the necktie 100, rather than the keeper loop 114 beingattached with two separate connection points at each end of the keeperloop 114. Also, a single tack stitch, called a bar tack 116, may be usedin some embodiments to stabilize, or possibly to provide strength to,interfacing of the necktie 100. A slip stitch (not shown), may be usedto sew a necktie 100 closed following folding and/or pinning.

As may be seen in the magnified image with respect to items 118, 120,and 122, a woven fabric is made of individual orthogonally orientedthreads 118 and 120. Each thread is made of multiple fibers. The threadsperpendicular to the direction of a fabric are called the warp 118, andthe threads along the length of a fabric are called the weft 120.Generally, woven fabrics have a bias 122. The bias 122 is an invisibleplane that intersects the warp 118 and the weft 120 at approximately 45degrees when the woven fabric is in approximately a relaxed state, freeof any application of stress or tension parallel or perpendicular to anaxis of elongation 106 (i.e., zero-point tension).

When a necktie 100 is tied, the fabric is pulled parallel to the axis ofelongation 106 and perpendicular to the axis of elongation 106. Thus, ifa necktie 100 were constructed with the centerline parallel to the warp118 or the weft 120, the fabric 102 may have a limited flexibility. Forexample, if the centerline of the necktie 100 is parallel to the warp118 or the weft 120, and if the fabric 102 is pulled parallel orperpendicular to the axis of elongation 106 beyond a threshold, thefabric 102 may tear. Additionally, the edges of the fabric 102 may havedifferent flexibilities. As a result, the fabric 102 may contort. For atleast these reasons, the centerline of a necktie 100, is typically alongthe bias 122, which is diagonal to the warp 118 and the weft 120, inorder to maximize the flexibility of the fabric 102.

In contrast with woven fabrics, knit fabrics have threads that arelooped and purled to form fabrics comprised of interlocking loops. In atleast some embodiments, since each thread in a knit fabric isinterlocked with its adjoining thread via interlocking stitches, knitfabric tends to be more flexible than woven fabrics. However, thisadvantage is negated where a knit fabric is bound to a woven fabric,since the flexibility of the combined fabrics is now limited by the lessflexible woven fabric.

Multi-Ply Apparel Neckpiece

The systems and/or processes described herein relate to a multi-plyapparel neckpiece. Specifically, the systems and/or processes describedherein describe an apparel neckpiece where, in at least one embodiment,different woven fabrics are sewn together with an attaching threadsubstantially along the warp and/or the weft of the woven fabrics. Insome embodiments, the attaching thread has a greater flexibility thanthe flexibility of the woven fabrics. As a result, the woven fabrics inwhich the attaching thread is sewn may return to their original shapeeven if the woven fabrics are repeatedly stretched and/or strained. Insome embodiments, when the attaching thread substantially follows thewarp and/or the weft of the woven fabrics, the attaching threads do notinhibit the flexibility of the bias. In this way, the flexibilities ofthe woven fabrics may be maintained without compromising the integrityof a seam of the woven fabrics. FIG. 2 illustrates an embodiment of themulti-ply apparel neckpiece 200 when the woven fabric is sewn with theattaching threads oriented substantially along the warp and/or weft of awoven fabric. While the descriptions herein describe woven fabrics, asimilar technique may also be used for knit fabrics.

In some embodiments, the apparel neckpiece 200 includes a first piece offabric 202 that may be on the front side 104 of the apparel neckpiece200 and a second piece of fabric 204 that may be on the back side of theapparel neckpiece 200. The first piece of fabric 202 may have a firstbias and the second piece of fabric 204 may have a second bias. Thefirst bias is the invisible plane that intersects the warp 118 and theweft 120 of the first piece of fabric at approximately 45 degrees. Thesecond bias is the invisible plane that intersects the warp 118 and theweft 120 of the second piece of fabric at approximately 45 degrees. Thefirst piece of fabric 202 may overlay the second piece of fabric 204such that the first bias and the second bias are substantially aligned.Both the first piece of fabric 202 and the second piece of fabric 204may be elongated and have an axis of elongation 106. The centerline 206of the necktie may be along the axis of elongation 106, parallel to thebias 122 of the pieces of fabric.

A consequence of having sewn edges on the apparel neckpiece 200 is thatthe apparel neckpiece 200 may be constructed from fabrics with a broadvariety of distortion threshold distances. In at least some embodiments,the distortion threshold distance may refer to the vertical and/orhorizontal elasticity of a fiber or fabric, or the ability of the fiberor fabric to return to its original length, shape, or size immediatelyor shortly after the removal of stress. In at least one embodiment, thefirst piece of fabric 202 and/or the second piece of fabric 204 mayinclude fabrics that are not typically used for making neckties,including but not limited to leather, fur, and artificial fur.Additionally, in some embodiments, dissimilar fabric or cloth types maybe used for an apparel neckpiece 200. Moreover, different, butcomplementary, pairs of fabric may be combined in an apparel neckpiece200 for aesthetic effect. Specifically, complementary fabrics arematerials that provide contrast in texture, thickness, or other fabricproperties (e.g., color, etc.). For example, leather paired with silkprovides a contrast in texture, sheen, and thickness.

Alternatively, in some embodiments, unmatched cloth types may be used intandem or in combination to simply provide contrast in pattern and/orprint. For example, one version of using unmatched cloth types is tomake a patchwork, where one or more scraps of different kinds of clothare sewn together into a single piece of fabric, and where contrastingscraps provide an aesthetic pattern. The different kinds of cloth mayhave different distortion threshold distances, or the distortionthreshold distances of the different kinds of cloth may be similar.

In at least some embodiments, additional pieces of fabric may be addedto the first piece of fabric 202 and/or second piece of fabric 204 toprovide backing, interfacing, or lining.

In some embodiments, the first piece of fabric 202 may display a patternon the front side 104 of the necktie 200 facing away from the wearer.The second piece of fabric 204 may be backing fabric added to the firstpiece of fabric 202 to provide a different color or pattern. In thisway, when the necktie is folded, the different patterns may provide anaesthetic effect. The backing fabric may offer support and/or heft tothe apparel neckpiece.

In at least one embodiment, an interfacing (not shown) may aid instiffening or adding heft to the necktie 200. In at least someembodiments, the interfacing may be a fabric added to the first piece offabric 202 and/or the second piece of fabric 204, for example, betweenthe first piece of fabric 202 and the second piece of fabric 204. Theinterfacing may be associated with, or affixed to, the first piece offabric 202 and/or the second piece of fabric 204 by a stitch, fuse,bond, etc. In at least some embodiments, the interfacing may not beattached at all, but may hang as a piece that may support the shape ofthe necktie 200 without being added to the first piece of fabric 202and/or the second piece of fabric 204. Furthermore, in some embodiments,the second piece of fabric 204 may offer support to the first piece offabric 202 and thus may eliminate the need for interfacing.

Lining is fabric that may be added to a first piece of fabric 202 toprovide a different color or pattern, but only in select portions of agarment. In the case of necktie apparel, the tip lining portion 110 inFIG. 1 is an example of lining.

In at least one embodiment, the first piece of fabric 202 and secondpiece of fabric 204 may have a proximate (i.e., close) edge and a distal(i.e., far) edge. Unlike a conventional necktie, at least part of eitherthe proximate or distal edges, or both, may be a sewn edge 208(exaggerated out of proportion to show the detail of the sewn edge).Specifically, the edge may be sewn with an attaching thread 210. Alength of the attaching thread 210 may be greater than a length of thefirst piece of fabric 202 and a length of the second piece of fabric 204when the first piece of fabric 202 and the second piece of fabric 204are elongated along the first bias and the second bias.

The attaching thread 210 may include a plurality of incision points 212and a plurality of interpoint threads 214. The plurality of incisionpoints 212 are the plurality of points where the attaching thread 210penetrates the first piece of fabric 202 and/or second piece of fabric204. A frequency of the plurality of incision points 212 (i.e., thenumber and spacing of the plurality of incision points 212 along theattaching thread 210) may depend on a predetermined distortion thresholddistance of the first piece of fabric 202 and/or a predetermineddistortion threshold distance of the second piece of fabric 204.

In at least some embodiments, two adjacent incision points 212 of theplurality of incision points 212 may be joined by an interpoint thread214 of the plurality of interpoint threads 214. In some embodiments, oneor more adjoining interpoint threads 214 may create an angle relative tothe first bias and the second bias, or the centerline 206. A measure ofthe angle may depend on a predetermined distortion threshold distance ofthe first piece of fabric 202 and/or a predetermined distortionthreshold distance of the second piece of fabric 204. Depending on thepredetermined distortion threshold distances, the measure of the anglemay be such that the angle may be an acute, obtuse, or approximatelyright angle.

As described in the context of FIG. 2, sewing the attaching thread 210such that it substantially follows the warp 118 and/or the weft 120 ofthe woven fabrics, may allow the attaching thread 210 to move freelywith the threads of the woven fabrics. Therefore, the flexibility of thewoven fabrics may be maintained without compromising the integrity ofthe woven fabrics. The techniques and systems described above permitdifferent fabrics to be sewn together to create unique neckties.

FIG. 3 illustrates an enlarged view of the sewn edge 208. The sewn edge208 may be located on the first piece of fabric 202 and/or the secondpiece of fabric 204. In FIG. 3, the attaching thread 210 is shown suchthat individual incision points 212 of the plurality of incision points212 are located on or near the sewn edge 208 of the piece of fabricshown. For the purpose of FIG. 3, the sewn edge 208 is parallel to thebias 122. A first interpoint thread 214 forms a first side of the anglerelative to the bias 122 and a second interpoint thread 214 forms asecond side of the angle relative to the bias 122. However, in someembodiments, one or more interpoint threads 214 may form the first sideof the angle relative to the bias 122 and one or more interpoint threads214 may form the second side of the angle relative to the bias 122. Insome embodiments, the sewn edge 208 may not be parallel to the bias 122,and in such embodiments, the angle formed by the interpoint threads 214may reference the bias 122 even though the sewn edge 108 may not.

In at least one embodiment, a stitch sufficient to withstand repeatedstretching may be sewn so that the attaching thread 210 follows the warp118 and/or weft 120 (i.e., the one or more adjoining interpoint threads214 form approximately a right angle). However, in some embodiments, theattaching thread 210 diverges from the warp 118 and/or the weft 120(i.e., the one or more adjoining interpoint threads 214 form acute orobtuse angles), and the attaching thread 210 may still form a stitchsufficient to withstand repeated stretching. The attaching thread 210may be sewn using a variety of stitches. For example, the attachingthread may be sewn using a chain stitch, a lock stitch, a cover stitch,a cross-stitch, etc.

In some embodiments the threads and/or fibers of a piece of fabric(e.g., 202 and/or 204) may be elastic and, thus, may easily change form(e.g., stretch, etc.). In such embodiments, the angle formed by theattaching thread 210 may be different from a right angle. Nevertheless,the attaching thread 210 and resulting angle may still form a stitchsufficient to withstand repeated stretching. For example, if either thefirst piece of fabric 202 or the second piece of fabric 204 has adistortion threshold distance such that, upon placing stress on thepiece of fabric (e.g., 202 and/or 204), the piece of fabric is stretchedso the threads comprising the fabric have a relatively long distance totravel to return to their original configuration (i.e., highelasticity), then the angle relative to the first bias and the secondbias may be an acute angle. In such an embodiment, the pieces of fabricmay have space between the threads and/or fibers making up the fabricand thus may have a relatively large distortion threshold distance.

In an alternative example, if either the first piece of fabric 202 orthe second piece of fabric 204 has a distortion threshold distance suchthat, upon placing stress on the piece of fabric (e.g., 202 and/or 204),the piece of fabric is stretched so the threads comprising the fabrichave a relatively short distance to travel to return to their originalconfiguration (i.e., low elasticity), then the angle relative to thefirst bias and the second bias may be an obtuse angle. In such anembodiment, the pieces of fabric may be more tightly woven and have arelatively small distortion threshold distance.

The measure of the angle relative to the first bias and the second biasmay vary depending on the distortion threshold distances of the firstpiece of fabric 202 and the second piece of fabric 204, as describedabove. Additionally, the measure of the angle relative to the first biasand the second bias may vary based on the elasticity of the first pieceof fabric 202 and the second piece of fabric 204, the elasticity of theindividual threads and/or fibers of the first piece of fabric 202 andthe second piece of fabric 204, and/or the density (i.e., thread count)by which the threads and/or fibers of the first piece of fabric 202 andthe second piece of fabric 204 are woven.

In FIG. 3, lines 302(1)-302(N) represent example placements forindividual incision points 212 of the plurality of incision points 212that are not located on the bias. Similarly, lines 304(1)-304(N)represent example placements for individual incision points 212 of theplurality of incision points 212 that are located on the bias. In bothembodiments, the lines are substantially parallel to the warp 118 and/orthe weft 120. That is, if the attaching thread 210 substantially followslines 302(1)-302(N) and 304(1)-304(N), the angle relative to the biasshould measure approximately a right angle with respect to the bias.However, as long as the incision points 212 are located either on orabove lines 302(1)-302(N) and 304(1)-304(N) (i.e., forming approximatelyright or acute angles with the bias), as shown in FIG. 3, the attachingthread 210 may still form a stitch sufficient to withstand repeatedstretching. In some embodiments, as described above, the incision points212 may be located below lines 302(1)-302(N) and 304(1)-304(N) (i.e.,forming an obtuse angle with the bias), and the attaching thread 210 maystill form a stitch sufficient to withstand repeated stretching. A sewnedge 208 similar to the one illustrated in FIG. 3 may be appropriatewhen the threads and/or fibers of a piece of fabric (e.g., 202 and/or204) are not elastic and/or do not easily change form. That is, FIG. 3illustrates a sewn edge 208 in an embodiment where the threads and/orfibers of the fabric are not flexible.

In some embodiments, the attaching thread 210 may be sewn in such a waythat the first piece of fabric 202 and second piece of fabric 204 are atsubstantively equal tension. When a fabric is not under any stress, thefabric is at zero-point tension (i.e., at rest, relaxed, etc.). Thus, inat least some embodiments, the attaching thread 210 may attach the firstpiece of fabric 202 and the second piece of fabric 204, such that whenboth fabrics are at zero-point tension, the fabrics do not pucker orotherwise distort the other fabric.

Generally, the tension of a stitch is regulated by a feed tensionassociated with a sewing machine. In at least some embodiments, theattaching thread 210 may be attached in such a way that the feed tensionmatches the zero-point tension of the first piece of fabric 202 and thesecond piece of fabric 204. For example, the attaching thread 210 may beattached such that when the attaching thread 210 is at rest, it does notplace stress on the first piece of fabric 202 and/or second piece offabric 204. As a result, when both pieces of fabric are at zero-pointtension, they do not pucker, or otherwise distort. In embodiments wherethe first piece of fabric 202 and/or the second piece of fabric 204include patchwork, the feed tension may vary throughout the sewn edge208 depending on the distortion threshold distance of the one or morescraps of the plurality of different kinds of fabric that make up thepatchwork.

Returning back to FIG. 2, in embodiments where the design may look likea conventional necktie, the sewn edges 208 may be limited to a knottingarea 216 and/or a neck area 218. When the necktie 200 is knotted, theknotting area 216 is the portion of the necktie 200 that comprises theknot, and the neck area 218 is the area of the necktie 200 that wrapsaround the wearer's neck. The knotting area 216 and the neck area 218are subject to a high degree of strain and tension with relation to theentire necktie 200, and accordingly benefit from the additionalflexibility afforded by sewn edges 208.

Additional Apparel Neckpieces Options Made Available with Sewn Edges

Sewn edges provide design options not available with conventionalneckties, such as undulating curves and necktie end storage designs.FIG. 4 provides an example 400 of undulating curves and articulationsnips. FIG. 5 provides two examples 500 and 502 of necktie end pockets.

FIG. 4 illustrates an undulating curve 400 associated with a necktie.Conventional neckties having hand-rolled edges rely on creases toprovide their form. Thus, conventional necktie edges are typicallystraight lines, and not curved. However, with sewn edges, a necktie neednot rely on creases, and therefore may have undulating curves (i.e.,curves that may turn in and/or out) with respect to the axis ofelongation 106. An example of a curve turning out is a convex curve 402.An example of a curve turning in is a concave curve 404. In someembodiments, undulating curves may be smooth and/or jagged.

A convex curve 402 may be implemented with articulation snips or notches406 that result in tabs 408. The articulation snips or notches 406 maybe cut when a front of the first piece of fabric 202 and a front of thesecond piece of fabric 204 are facing one another (i.e., when thenecktie is inside-out). The tabs 408 may be folded in, without pleatingor bunching of the fabric (e.g., 202, 204) to provide a finished sewnedge 208 resulting in a convex curve 402.

A concave curve 404 may be implemented with articulation snips ornotches 406 that result in the tabs 408. The articulation snips ornotches 406 may be cut when a front of the first piece of fabric 202 anda front of the second piece of fabric 204 are facing one another (i.e.,when the necktie is inside-out). The tabs 408 may be folded in, withoutpleating or bunching of the fabric (e.g., 202, 204), to provide afinished sewn edge 208 resulting in a concave curve 404.

In at least one embodiment of constructing an apparel neckpiece, a firstpiece of fabric 202, typically the front side 104 of the apparelneckpiece 100 and a second piece of fabric 204, typically the back sideof the apparel neckpiece, are cut having matching curves. The two piecesof fabric may be aligned with their curves matching. The edges are thensewn as described above with the resulting concave and/or convex curves.The articulation snips or notches 406 then may be cut and folded in, asdescribed above.

FIG. 5 illustrates two examples 500 and 502 showing necktie end pocketoptions. A conventional necktie relies on a keeper loop to keep the backend of a necktie, typically a narrower end of a necktie, in alignmentwith the front end of a necktie, typically a broader end of a necktie.In contrast, in at least one embodiment, a multi-ply necktie may have afull necktie end pocket. A full necktie end pocket is a mechanism thatholds one end of the necktie in place by inserting a first end of thenecktie into the full necktie end pocket on a second end of the necktiethat is opposite the first end of the necktie.

A bezel necktie pocket 500 corresponds to a pocket 504 that may hold anecktie end by virtue of the first piece of fabric 202 and the secondpiece of fabric 204 being sewn together (the dotted line illustrateswhere a back end of the necktie would be situated between the firstpiece of fabric 202 and the second piece of fabric 204). The pocket maybe constructed with a slit 506 that is finished to prevent fraying. Inthe illustration 500, a finished edge is applied to slit 506.

Another variation of a full necktie pocket is a full width pocket 508(the dotted line illustrates where a back end of the necktie would besituated between the first piece of fabric 202 and the second piece offabric 204). In a full width pocket 508, a formal pocket may beconstructed by inserting an additional piece of fabric between the firstpiece of fabric 202 and the second piece of fabric 204 and sewing thesides and bottom edges. In at least one embodiment, a front side of theadditional piece of fabric may face the front side of the first piece offabric 202 when the first piece of fabric 202 and second piece of fabric204 are sewn facing one another (i.e., when the necktie is inside-out).Alternatively, where the bottom edge may be a straight edge, the bottomof the front end of the necktie may be folded up with the sides sewn tomake a pocket. The sewing may occur when a front of the first piece offabric 202 and a front of the second piece of fabric 204 are facing oneanother (i.e., when the necktie is inside-out). The top of the fullwidth pocket 508 may be cut straight across, or as in the illustration502, may be cut at an angle. These designs allow one end of a necktie tohold an opposite end of the necktie in place via a full necktie endpocket mechanism.

Manufacturing Processes for a Shape Preserving Apparel Neckpiece

Portions of the previous discussion have been directed to describing anapparel neckpiece with at least one sewn edge 208. Turning to FIG. 6, aflow chart 600 describes a nonlimiting example process for manufacturingan apparel neckpiece with at least one sewn edge 208.

Block 602 illustrates determining a first distortion threshold distanceof a first piece of fabric 202 having a first warp 118 and a first weft120. A first piece of fabric 202 is selected and a distortion thresholddistance of the fabric is measured. The first piece of fabric 202 iselongated as to be suitable for an apparel neckpiece, and long enough tohave a portion of the fabric designated for knotting. The first piece offabric 202 may have two long edges, one proximate and the other distal.The first piece of fabric 202 may be made of any of the types of fabricdescribed above. As a nonlimiting example, the first piece of fabric 202could be knit or woven, a single piece of fabric, or a patchwork fabric.The first piece of fabric 202 could be made of fibers that havesubstantial elasticity or minimal elasticity (i.e., varying distortionthreshold distances).

Block 604 illustrates determining a second distortion threshold distanceof a second piece of fabric 204 having a second warp 118 and a secondweft 120. A second piece of fabric 204 is selected, and its respectivedistortion threshold distance is measured. As with the first piece offabric 202, the second piece of fabric 204 is also elongated as to besuitable for an apparel neckpiece, and long enough to have a portion ofthe fabric designated for knotting. As with the first piece of fabric202, the second piece of fabric 204 may also have two long edges, oneproximate and the other distal. The second piece of fabric 204 may bemade of any of the types of fabric described above. As a nonlimitingexample, the second piece of fabric 204 could be knit or woven, a singlepiece of fabric, or a patchwork fabric. The second piece of fabric 204could be made of fibers that have substantial elasticity or minimalelasticity (i.e., varying distortion threshold distances). Furthermore,the second piece of fabric 204 could be a same type of fabric with samecharacteristics as the first piece of fabric 202, or could be adifferent type of fabric having different characteristics from the firstpiece of fabric 202.

In some embodiments, either the first piece of fabric 202 or the secondpiece of fabric 204 may be folded at least one time such that either thefirst piece of fabric 202 and/or the second piece of fabric 204 maycomprise one or more layers of fabric. In such embodiments, the foldsmay be secured. For example, the folds may be secured with a sewn edge208 as described above. The sewn edge 208 may be a straight sewn edge(i.e., the sewn edge 208 is parallel to the bias) or the sewn edge 208may follow undulating curves as described above.

Block 606 illustrates overlaying the first piece of fabric 202 with thesecond piece of fabric 204 such that the first warp and first weftsubstantially align with the second warp and the second weft. The firstpiece of fabric 202 and the second piece of fabric 204 may be overlaidwith the proximate edge of the first piece of fabric 202 substantiallyaligned with the proximate edge of the second piece of fabric 204, andthe distal edge of the first piece of fabric 202 substantially alignedwith the distal edge of the second piece of fabric 204. That is, thefirst piece of fabric 202 and the second piece of fabric 204 areoverlaid such that the first warp 118 and the first weft 120 of thefirst piece of fabric 202 substantially align with the second warp 118and the second weft 120 of the second piece of fabric 204.

Block 608 illustrates, based on the first distortion threshold distanceand the second distortion threshold distance, sewing an edgesubstantially parallel to an elongated edge of the first piece of fabric202 and the second piece of fabric 204. In at least one embodiment, afront side of the first piece of fabric 202 and a front side of thesecond piece of fabric 204 are facing one another (i.e., the edge issewn when the necktie is inside-out).

The aligned proximate edges of the first piece of fabric 202 and thesecond piece of fabric 204 may be sewn together with an attaching thread210. Similarly, the aligned distal edges of the first piece of fabric202 and the second piece of fabric 204 also may be sewn together with anattaching thread 210. As described above, the measure of the angle oftwo or more adjoining interpoint threads 214 of the attaching thread 210are based at least in part on the predetermined distortion thresholddistance of the first piece of fabric 202 and the second piece of fabric204. As described above, when the first piece of fabric 202 or thesecond piece of fabric 204 are made of less elastic fibers, theinterpoint threads 214 may be sewn to create an obtuse angle with thebias 122, regardless of the shape or location of the seam line. Inalternative embodiments, when the first piece of fabric 202 and/or thesecond piece of fabric 204 are made of highly elastic fibers, theinterpoint threads 214 may be sewn to create an acute angle with thebias 122, regardless of the shape or location of the seam line. In atleast some embodiments, the length of the attaching thread 210 mayexceed the length of the first piece of fabric 202 and/or second pieceof fabric 204 when the fabrics are elongated along the first bias 122and the second bias 122.

As discussed above, the sewn edge 208 may be sewn when the first pieceof fabric 202 and second piece of fabric 204 are at substantially equaltension, such that when both fabrics are at zero-point tension, thefabrics do not pucker or otherwise distort the other fabric.Additionally, in at least some embodiments, the attaching thread 210 maybe sewn in such a way that the feed tension matches the zero-pointtension of the first piece of fabric 202 and the second piece of fabric204.

In some embodiments, the aligned proximate edges and the aligned distaledges need not be sewn in entirety. For example, the edges of theknotting area may be selected for sewing leaving the rest of theproximate and distal edges to be handrolled as in a conventionalnecktie. Additionally, the edges of the neck area may be selected forsewing, leaving the rest of the proximate and distal edges to be handrolled, sewn, or fused as in a conventional necktie.

Additionally, in some embodiments, additional fabric can be left outsideof the sewn edge 208 that may include stitches and/or folds to provideheft and/or durability to the apparel neckpiece.

Hoops or another stabilizing apparatus may be used to aid in sewing.Specifically, the first piece of fabric 202 and second piece of fabric204 may be fastened inside two concentric sewing hoops prior to sewingto ensure the fabric pieces do not move during sewing.

In general, apparel neckpieces may be mass produced by machines used forprecutting the first piece of fabric 202 and the second piece of fabric204. The first piece of fabric 202 and the second piece of fabric 204may be stabilized for sewing as described above and may be sewn using anattaching thread 210 comprising a plurality of incision points 212 and aplurality of interpoint threads 214. In at least some embodiments, amachine may sew the first piece of fabric 202 to the second piece offabric 204 prior to cutting the first piece of fabric 202 and the secondpiece of fabric 204 to form the apparel neckpiece. As described above,one or more adjacent interpoint threads 214 may comprise an anglerelative to the bias wherein the measure of the angle is based at leastin part on the distortion threshold distances of the first piece offabric 202 and second piece of fabric 204. Undulating curves and/orpockets may be executed as described with respect to FIGS. 5 and 6,respectively.

Block 610 illustrates pressing the first piece of fabric 202 and thesecond piece of fabric 204 to finish the apparel neckpiece. As describedabove, the necktie may be sewn such that a front side of the first pieceof fabric 202 and a front side of the second piece of fabric 204 arefacing one another (i.e., the necktie is sewn inside-out). Once thesewing is complete, the necktie may be turned right-side out so that thefront side of the first piece of fabric 202 and the front side of thesecond piece of fabric 204 are showing. Finally, apparel neckpieces maybe machine pressed.

CONCLUSION

Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the specific features or acts described above.Rather, the specific features and acts described above are disclosed asexample forms of implementing the claims.

What is claimed is:
 1. A sewn edge on a necktie apparel defined by: anattaching thread that attaches a first piece of fabric having a firstbias to a second piece of fabric having a second bias, the first pieceof fabric overlaying the second piece of fabric such that the first biasand the second bias are substantially aligned, the attaching threadcomprising: a plurality of incision points that penetrate the firstpiece of fabric and the second piece of fabric; and a plurality ofinterpoint threads, wherein: a particular interpoint thread of theplurality of interpoint threads joins a first incision point of theplurality of incision points to a second adjacent incision point of theplurality of incision points; and one or more adjoining interpointthreads of the plurality of interpoint threads comprise an anglerelative to the first bias and the second bias.
 2. The sewn edge ofclaim 1, wherein a measure of the angle is based at least in part on afirst predetermined distortion threshold distance of the first piece offabric and a second predetermined distortion threshold distance of thesecond piece of fabric.
 3. The sewn edge of claim 1, wherein a frequencyof the plurality of incision points is based at least in part on a firstpredetermined distortion threshold distance of the first piece of fabricand a second predetermined distortion threshold distance of the secondpiece of fabric.
 4. The sewn edge of claim 1, wherein the angle is anobtuse angle when the first piece of fabric, the second piece of fabric,or both the first piece of fabric and the second piece of fabric have adistortion threshold distance that is determined to be at or below athreshold.
 5. The sewn edge of claim 1, wherein: the first piece offabric has a first warp and a first weft; the second piece of fabric hasa second warp and a second weft, the first warp and the first weft beingsubstantially aligned with the second warp and the second weft; and thetwo adjoining interpoint threads of the plurality of interpoint threadsare sewn substantially along the first warp and the second warp and thefirst weft and the second weft such as to form approximately a rightangle relative to the first bias and the second bias.
 6. The sewn edgeof claim 1, wherein the angle is an acute angle.
 7. The sewn edge ofclaim 1, wherein a length of the attaching thread is greater than alength of the first piece of fabric and a length of the second piece offabric when the first piece of fabric and the second piece of fabric areelongated along the first bias and the second bias.
 8. An apparelneckpiece, comprising: a first piece of fabric having a first warp, afirst weft, and a first bias; a second piece of fabric having a secondwarp, a second weft, and a second bias, wherein the first piece offabric overlays the second piece of fabric such that the first warp, thefirst weft, and the first bias are substantially aligned with the secondwarp, the second weft, and the second bias; and a sewn edge defined by aplurality of incision points and a plurality of interpoint threads,wherein: the plurality of incision points penetrate the first piece offabric and the second piece of fabric; a particular interpoint thread ofthe plurality of interpoint threads joins a first incision point of theplurality of incision points to a second adjacent incision point of theplurality of incision points; and two or more interpoint threads of theplurality of interpoint threads form an angle relative to the first biasand the second bias.
 9. The apparel neckpiece of claim 8, wherein ameasure of the angle is based at least in part on a first predetermineddistortion threshold distance of the first piece of fabric and a secondpredetermined distortion threshold distance of the second piece offabric.
 10. The apparel neckpiece of claim 8, wherein the first piece offabric is a front fabric and the second piece of fabric is at least oneof: a backing fabric; an interfacing fabric; or a lining fabric.
 11. Theapparel neckpiece of claim 8, wherein the sewn edge is limited to aknotting area of the apparel neckpiece.
 12. The apparel neckpiece ofclaim 8, wherein the sewn edge is limited to a neck area of the apparelneckpiece.
 13. The apparel neckpiece of claim 8, wherein the first pieceof fabric, the second piece of fabric, or both the first piece of fabricand the second piece of fabric is a patchwork fabric.
 14. The apparelneckpiece of claim 8, wherein a substantial length of the first piece offabric and the second piece of fabric includes matching undulatingcurves.
 15. The apparel neckpiece of claim 14, wherein the matchingundulating curves of the first piece of fabric and the second piece offabric are executed with articulation snips.
 16. The apparel neckpieceof claim 8, wherein the apparel neckpiece includes a first end and asecond end, the first end including a pocket for the second end.
 17. Amethod comprising: determining a first distortion threshold distance ofa first piece of fabric, the first piece of fabric having a first warpand a first weft; determining a second distortion threshold distance ofa second piece of fabric, the second piece of fabric having a secondwarp and a second weft; overlaying the first piece of fabric with thesecond piece of fabric such that the first warp and first weftsubstantially align with the second warp and second weft; and sewing anedge parallel to an elongated edge of the first piece of fabricoverlaying the second piece of fabric, the edge defined by a pluralityof incision points and a plurality of interpoint threads, wherein: theplurality of incision points penetrate the first piece of fabric and thesecond piece of fabric; a particular interpoint thread of the pluralityof interpoint threads joins a first incision point of the plurality ofincision points to a second adjacent incision point of the plurality ofincision points; and two or more adjoining interpoint threads form anangle relative to a first bias of the first piece of fabric and a secondbias of the second piece of fabric, a measure of the angle being basedat least in part on the first distortion threshold distance and thesecond distortion threshold distance.
 18. The method of claim 17,wherein sewing the edge parallel to the elongated edge of the firstpiece of fabric overlaying the second piece of fabric comprises: sewingthe edge such that the first piece of fabric and the second piece offabric are at zero-point tension; and sewing the edge such that a feedtension corresponds to the zero-point tension.
 19. The method of claim17, wherein the two adjoining interpoint threads are sewn substantiallyalong the first warp and the second warp and the first weft and thesecond weft to form approximately a right angle relative to the firstbias and the second bias.
 20. The method of claim 17, wherein theplurality of incision points and the plurality of interpoint threadscomprise an attaching thread and a length of the attaching thread isgreater than a length of the first piece of fabric and a length of thesecond piece of fabric when the first piece of fabric and the secondpiece of fabric are elongated along the first bias and the second bias.